Binder compositions and uses thereof

ABSTRACT

The present disclosure provides for aqueous, curable binder compositions, as well as articles and products comprising assemblies of matter comprising mineral fibers, synthetic fibers, natural fibers, cellulosic particles and sheet materials comprising the binder compositions disclosed herein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/771,779, filed Apr. 27, 2018, which is a U.S. national counterpartapplication of International Application Serial No. PCT/EP2016/075823,filed Oct. 26, 2016, under 35 U.S.C. § 371, which claims priority to GBApplication Serial No. 1519187.7, filed Oct. 30, 2015, the disclosuresof which are hereby incorporated herein by reference.

SUMMARY OF THE INVENTION

The present disclosure provides for improved binder compositions,including curable binder compositions for use in manufacturing productsfrom a collection of non-assembled or loosely assembled matter. Forexample, these binder compositions may be employed to product fiberproducts which may be made from woven and non-woven fibers. In someembodiments, the binder compositions disclosed herein are used to bindglass fibers to produce fiberglass. In further embodiments, thedisclosed binder compositions are used to bind mineral wool fibers, suchas glass wool or stone wool, to form a matted layer for the productionof an insulating product. In still further embodiments, the bindercompositions disclosed herein are used to produce wood fiber boards,particle boards and oriented strand boards (OSBs) characterized byimproved physical properties (e.g., enhanced mechanical strength).Further, the binders may be used to assemble sheets of cellulosicmaterial, such as sheets of wood, to manufacture plywood. Additionally,processes for binding loosely assembled matter and producing articlesfrom loosely assembled matter bound using the binder compositions areprovided.

Formaldehyde-free binder compositions have previously been reported,including curable, formaldehyde-free binder compositions comprising oneor more of sustainable materials, polyacids, anhydrides, polyhydroxylcomponents, polyamines, carbohydrates, derivatives thereof, andadditional components such as silicon comprising compounds. However,formaldehyde-free binders and resins may be characterized by adisadvantageous coloration, e.g. upon curing, which may not becommercially desirable. In addition, previously disclosedformaldehyde-free binders may lack sufficient bond strength whiledisadvantageously increasing binder production costs.

In some embodiments, the present disclosure provides for an assembly ofmatter comprising one or more of mineral fibers, synthetic fibers,natural fibers, cellulosic particle materials, and sheet materials,characterized by improved properties including but not limited to thereduction or elimination of undesirable coloration and improvedmechanical properties.

In further embodiments, a process for the preparation of an assembly ofmatter as described herein is provided.

In still further embodiments, a cost-effective process for thecommercial production of the disclosed formaldehyde-free bindercompositions, which are alternatively referred to herein as “binders”and “binder compositions,” is provided.

In additional embodiments, an improved, formaldehyde-free bindercomposition produced using renewable and/or sustainable feedstocks andcomponents is provided.

In certain embodiments, formaldehyde-free binder compositions capable ofrapidly curing and providing sufficient commercial strength areprovided.

In some embodiments, commercial products and articles comprising thedisclosed formaldehyde-free binders are disclosed.

In certain embodiments, the commercial articles and products of thepresent disclosure may comprise an assembly of matter comprising one ormore of mineral fibers, synthetic fibers, natural fibers, cellulosicparticle materials and sheet materials bonded together by a bindercomposition disclosed herein, including an aqueous curable bindercomposition comprising a monosaccharide or polysaccharide and anazetidinium crosslinker. In additional embodiments, a binder compositionas disclosed herein may comprise one or more reaction products resultingfrom one or more crosslinking reactions between a monosaccharide and/ora polysaccharide and an azetidinium crosslinker.

DETAILED DESCRIPTION OF THE INVENTION

In some embodiments, a monosaccharide for use in the disclosedtechnology may comprise a 5-carbon monosaccharide or a 6-carbonmonosaccharide such as dextrose. In further embodiments, apolysaccharide of the present disclosure may comprise at least twosaccharide units, including at least four saccharide units and up to 10⁶saccharide units, such as up to 3000 saccharide units, 5000 saccharideunits and 10000 saccharide units, such as native starch and starchderivatives. Starch generally comprises two different polymers ofD-glucopyranose, amylose and amylopectin. Amylose is a linearpolysaccharide, while amylopectin is a highly branched polysaccharide.Amylose has a relatively low molecular weight with a degree ofpolymerization ranging from 1000 to 10000 glucose units and a molecularweight (MW) of greater than 10⁶ g/mol, while amylopectin is a largerbranched polysaccharide with a degree of polymerization of greater than10⁵ and a molecular weight (MW) of greater than 10⁷ g/mol. In additionalembodiments, starch derivatives for use in the disclosed technology maycomprise one or more of starch ethers such as carboxymethyl starches,hydroxyalkyl starches, cationic starches, amphoteric starches, starchesters such as starch acetates, starch phosphates, starch octenylsuccinate, acid modified starch, oxide modified starch, and partiallyhydrolysed starches such as dextrins. In certain embodiments,polysaccharides for use in the present disclosure may be derived fromcellulose and other natural or synthetic sources, including chitin.Starch derivatives such as dextrins and maltodextrins comprise D-glucoseunits linked in chains of variable lengths, for instance from 2 to 20glucose units.

In some embodiments, azetidinium crosslinkers may be utilized. As wouldbe known to those of skill in relevant arts, multifunctional azetidiniumcrosslinker may be prepared using different coupling agents and aminefunctional monomers with different ratios, including the use of at leastone substituted or unsubstituted, four-membered nitrogen comprisingheterocycle. In further embodiments, an azetidinium group may bechemically bonded to a homopolymer or a copolymer chain comprising oneor more nonazetidinium monomer units incorporated into the polymerstructure. In still further embodiments, an azetidinium crosslinker foruse in the instant disclosure may comprise at least two azetidiniumgroups. An azetidinium polymer for use in the present disclosure maycomprise the general structure below:

wherein 1) n is an integer greater than or equal to 1, 2) R₁ comprisesan C₁-C₂₅ alkanediyl group, such as a C₁-C₁₀ alkanediyl group or a C₁-C₅alkanediyl group that may be optionally substituted with a hydroxylgroup, a carboxyl group or an amine group, 3) R₂ may be independently R1or —R₃—NH—C(O)—R₄—, with R₃ and R₄ independently comprising a C₁-C₂₅alkanediyl group, such as a C₁-C₁₀ alkanediyl group or a C₁-C₅alkanediyl group, 4) Y₁ and Y₃ comprise a hydrogen (H) group or a C₁-C₅alkyl group that may be optionally substituted with a hydroxyl group, anamine or a carboxyl group, 5) Y2 comprises a hydroxyl (OH—) group or achemical group as defined by Y1, and 6) X⁻ comprises a halogen ion.

As would be appreciated by those of skill in the relevant arts,azetidinium functionalized polymers comprise highly reactive quaternaryammonium groups, which in certain embodiments may improve embodimentsand properties of products and articles comprising the binders disclosedherein, including but not limited to antimicrobial activity. While in noway limiting the scope of the present disclosure, it is believed thatthe reactivity of azetidinium functional groups may be due to in part toangle strain, which may beneficially increase its reactivity withnucleophiles. In additional embodiments, azetidinium crosslinkers foruse in the instant disclosure may polymerize at elevated temperaturesand/or by radical initiation.

In some embodiments, the dry weight ratio of monosaccharide and/orpolysaccharide to azetidinium crosslinker comprises a range of 99:1 to60:40, such as a range of 98:2 to 70:30 and a range of 95:5 to 75:25.

In additional embodiments, the aqueous binder compositions disclosedherein exhibit unexpectedly high bond strength upon curing. The loss ofbond strength after weathering may be significantly reduced as comparedto prior art thermoset binders.

The bond strength of a veil product bonded with invention bindercompositions may be slightly affected by the pH of the composition,notably at lower relative azetidinium content. More particularly,alkaline pH of the binder composition has a tendency to slightly reducethe bond strength (dry and wet) while acidic pH pushes the bond strengthup, at higher starch/azetidinium ratios.

In some embodiments, an aqueous binder composition as disclosed hereincomprises one or more mono- and/or polysaccharide(s) crosslinked by anazetidinium crosslinker and further comprises a crosslinker capable ofundergoing free radical polymerization selected from the groupconsisting of polycarboxylic acids, acrylamides, methacrylamides,acrylates, acrylic acids, acrylonitrile, bisphenol acrylics,carbohydrate monomers, fluorinated acrylics, maleimide, polyfunctionalacrylics, salts thereof and mixtures thereof. In certain embodimentswhere free radical polymerization is initiated by a free radicalinitiator, the aqueous binder composition may further comprise one ormore free radical initiator(s) for the initiation of an increased numberof crosslinking reactions between the saccharide residues and thecrosslinker. Such crosslinking reactions may be initiated by introducinga sufficient amount of energy, including heat and/or radiation, into theaqueous binder composition to generate a highly crosslinked resin whichconfers improved bond strength upon curing to an assembly of matter,composition or article in accordance with the present disclosure. Inaccordance with the present disclosure, a two-stage polymerizationprocess comprising a second step of free radical polymerization providesa highly polymerized resin characterized by an advantageously increasedpolymerization density in articles and materials comprising fibers,cellulosic particulates and/or sheet materials.

In some embodiments, the binder compositions disclosed herein mayadvantageously reduce the energy cost and/or production time associatedwith bonding and subsequently curing of articles and products comprisingfibers and cellulosic particulate or sheet materials.

In certain embodiments, a polycarboxylic acid for use in the disclosedtechnology may be selected from monomeric and polymeric polycarboxylicacids, unsaturated aliphatic dicarboxylic acids, saturated aliphaticdicarboxylic acids, aromatic dicarboxylic acids, unsaturated cyclicdicarboxylic acids and saturated cyclic dicarboxylic acids, any of whichmay be optionally substituted with hydroxy, halo, amino, alkyl, carboxy,alkoxy, and anhydride groups, as well as salts, esters and mixturesthereof. In further embodiments, one or more polycarboxylic acids foruse in the disclosed binder compositions is selected from the groupconsisting of malic acid, glutamic acid, glutaconic acid,3-fumarylpyruvic acid, 2,5-furandicarboxylic acid, mesaconic acid,mesoxalic acid, glutaric acid, nedocromil,4-(gamma-glutamylamino)butanoic acid, neoglutyl, succinic acid, aconiticacid, adipic acid, azelaic acid, butane tetracarboxylic acid dihydride,butane tricarboxylic acid, chlorendic acid, citraconic acid,dicyclopentadiene-maleic acid adducts, diethylenetriamine pentaaceticacid, adducts of dipentene and maleic acid, ethylenediamine tetraaceticacid (EDTA), fully maleated rosin, maleated tall-oil fatty acids,fumaric acid, glutaric acid, isophthalic acid, itaconic acid, maleatedrosin oxidized with potassium peroxide to produce an alcohol capable ofbeing further oxidized to a carboxylic acid, maleic acid, malic acid,mesaconic acid, biphenol A or bisphenol F reacted via the Kolbe-Schmittreaction with carbon dioxide to introduce 3-4 carboxyl groups, oxalicacid, phthalic acid, sebacic acid, succinic acid, tartaric acid,terephthalic acid, tetrabromophthalic acid, tetrachlorophthalic acid,tetrahydrophthalic acid, trimellitic acid, trimesic acid, salts andanhydrides thereof, and combinations thereof. In further embodiments, apolymeric polycarboxylic acid for use in the disclosed binders isselected from polyacrylic acid, polymethacrylic acid, polymaleic acid,copolymers thereof, anhydrides thereof, and mixtures thereof. Examplesof commercially available polyacrylic acids include AQUASET™ 529 (Rohm &Haas, Philadelphia, Pa., USA), CRITERION 2000 (Kemira, Helsinki,Finland, Europe), NF1 (H. B. Fuller, St. Paul, Minn., USA), and Sokalan®(BASF, Ludwigshafen, Germany), which is a water-soluble polyacryliccopolymer of acrylic acid and maleic acid having a molecular weight ofapproximately 4000. AQUASET® 529 is a composition containing polyacrylicacid cross-linked with glycerol and sodium hypophosphite as a catalyst.CRITERION 2000 is an acidic solution of a partial salt of polyacrylicacid, having a molecular weight of approximately 2000. NF1 is acopolymer containing carboxylic acid and hydroxy groups, as well aschain transfer agents such as sodium hypophosphite or organophosphatecatalysts. The polymeric polycarboxylic acid may be a homopolymer orcopolymer prepared from unsaturated carboxylic acids including, but notlimited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonicacid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid,2-methylitaconic acid and α, β-methyleneglutaric acid. Alternatively,the polymeric polycarboxylic acid may be prepared from unsaturatedanhydrides including, but not limited to, maleic anhydride, itaconicanhydride, acrylic anhydride, methacrylic anhydride and mixturesthereof. Methods for polymerizing these acids and anhydrides are wellknown in the chemical arts. In some embodiments, a polymericpolycarboxylic acid for use in the disclosed technology may additionallycomprise a copolymer of one or more of the unsaturated carboxylic acidsor anhydrides and one or more vinyl compounds disclosed herein includingstyrene, α-methylstyrene, acrylonitrile, methacrylonitrile, methylacrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, methylmethacrylate, n-butyl methacrylate, isobutyl methacrylate, glycidylmethacrylate, vinyl methyl ether and vinyl acetate. The molecular weightof the polymeric polycarboxylic acids and polyacrylic acid polymers maybe less than 10000 Daltons (Da), less than 5000 Da, or about 3000 Da orless, including 2000 Da.

In some embodiments, acrylamide and methacrylamide monomers for use inthe disclosed binder compositions may be selected from the groupconsisting of alkylacrylamide, N-tert-butylacrylamide, diacetoneacrylamide, N,N-diethylacrylami de, N,N-diethylmethacrylamide,N,N-dimethylacrylamide, N-[3-(dimethylamino)propyl]methacrylamide,N-diphenylmethylacrylamide, Nethylacrylamide,N,N′-hexamethylenebis(methacrylamide), N-hydroxyethyl acrylamide,N-(hydroxymethyl)acrylamide,N-(2-hydroxypropyl)-2-methyl-prop-2-enamide,N-(isobutoxymethyl)-acrylamide, N-isopropylacrylamide,N-isopropylmethacrylamide, methacrylamide,N-(3-methoxypropyl)acrylamide, N-phenylacrylamide,2-acrylamido-2-methyl-1-propanesulfonic acid, 3-(acrylamido)phenylboronic acid, Nacryloylamidoethoxyethanol,N-(triphenylmethyl)-methacrylamide,Ntris(hydroxymethyl)methyl]-acrylamide and salts thereof.

In further embodiments, acrylate monomers may be selected from the groupconsisting of 4-acetoxyphenethyl acrylate, 4-acryloylmorpholine, butylacrylate, 2-(4-benzoyl-3-hydroxyphenoxy)ethyl acrylate, benzyl2-propylacrylate, tert-butyl acrylate,2-[[(butylamino)carbonyl]oxy]ethyl acrylate, 4-tert-butylcyclohexylacrylate, 2-carboxyethyl acrylate, 2-(diethylamino)ethyl acrylate,di(ethylene glycol) ethyl ether acrylate, di(ethylene glycol)2-ethylhexyl ether acrylate, 2-(dimethyl amino)ethyl acrylate,3-([[D]]dimethylamino)propyl acrylate, dipentaerythritolpenta-/hexa-acrylate, ethyl acrylate, ethyl cis-(β-cyano)acrylate,ethylene glycol dicyclopentenyl ether acrylate, ethylene glycol methylether acrylate, ethylene glycol phenyl ether acrylate, ethyl2-ethylacrylate, 2-ethylhexyl acrylate, ethyl 2-propylacrylate, ethyl2-(trimethylsilylmethyl)acrylate, hexyl acrylate, 4-hydroxybutylacrylate, 2-hydroxyethyl acrylate, 2-hydroxy-3-phenoxypropyl acrylate,hydroxypropyl acrylate, isobutyl acrylate, isodecyl acrylate, isooctylacrylate, lauryl acrylate, methyl 2-acetamidoacrylate, methyl acrylate,methyl 3-hydroxy-2-methylenebutyrate, octadecyl acrylate, poly(ethyleneglycol) acrylate, poly(ethylene glycol) diacrylate, poly(ethyleneglycol) methyl ether acrylate, poly(propylene glycol) acrylate,3-sulfopropyl acrylate, tetrahydrofurfuryl acrylate, 2-tetrahydropyranylacrylate, 3-(trimethoxysilyl)propyl acrylate, 3,5,5-trimethylhexylacrylate, 10-undecenyl acrylate, urethane acrylate methacrylate andsalts thereof.

In some embodiments, methacrylate monomers for use in the bindersdisclosed herein may be selected from the group consisting of allylmethacrylate, aminoethyl methacrylate,2-[3-(2H-benzotriazol-2-yl)-4-hydroxyphenyl]ethyl methacrylate, benzylmethacrylate, bis(2-methacryloyl)oxyethyl disulfide,bis(2-methacryloyl)oxy ethyl di sulfide, 2-(2-bromoisobutyryloxy)ethylmethacrylate, 2-(tert-butylamino)ethyl methacrylate, butyl methacrylate,tert-butyl methacrylate, carbazole-9-ethylmethacrylate,3-chloro-2-hydroxypropyl methacrylate, cyclohexyl methacrylate,2-(diethylamino)ethyl methacrylate, diethylene glycol butyl ethermethacrylate, di(ethylene glycol) methyl ether methacrylate,2-(diisopropylamino)ethyl methacrylate, 2-(dimethylamino)ethylmethacrylate, 2-ethoxyethyl methacrylate, ethylene glycoldicyclopentenyl ether methacrylate, ethylene glycol methacrylatephosphate, ethylene glycol methyl ether methacrylate, ethylene glycolphenyl ether methacrylate, ethylhexyl methacrylate, ethyl methacrylate,furfuryl methacrylate, glycidyl methacrylate, glycosyloxyethylmethacrylate, hexyl methacrylate, hydroxybutyl methacrylate,hydroxyethyl methacrylate, hydroxypropyl methacrylate, hydroxypropylmethacrylates, 2-hydroxypropyl 2-(methacryloyloxy)ethyl phthalate,2-hydroxy-3-{3-[2,4,6,8-tetramethyl-4,6,8-tris(propyl glycidylether)-2-cyclotetrasiloxanyl]propoxy}propyl methacrylate, isobutylmethacrylate, 2-isocyanatoethyl methacrylate, isodecyl methacrylate,lauryl methacrylate, methacrylic acid N-hydroxysuccinimide ester, methylmethacrylate, 2-(methylthio)ethyl methacrylate,mono-2-(methacryloyloxy)ethyl maleate, mono-2-(methacryloyloxy)ethylsuccinate, 2-N-morpholinoethyl methacrylate, naphthyl methacrylate,2-(2-oxo-1-imidazolidinyl)ethyl methacrylate, pentabromophenylmethacrylate, 1,4-phenylene dimethacrylate, phenyl methacrylate,phosphoric acid 2-hydroxyethyl methacrylate ester, poly(ethylene glycol)behenyl ether methacrylate, poly(propylene glycol) methacrylate, propylmethacrylate, 1-pyrenemethyl methacrylate, stearyl methacrylate,3-sulfopropyl methacrylate, 3-(trimethoxysilyl)propyl methacrylate,3,3,5-trimethylcyclohexyl methacrylate, (trimethylsilyl)methacrylate,urethane acrylate methacrylate, urethane epoxy methacrylate, vinylmethacrylate and salts thereof.

In some embodiments, polyfunctional acrylics may be used ascrosslinkers, including those selected from the group consisting of3-(acryloyloxy)-2-hydroxypropyl methacrylate,bis[2-(methacryloyloxy)ethyl] phosphate, bisphenol A propoxylatediacrylate, 1,3- and 1,4-butanediol diacrylate, 1,3- and 1,4-butanedioldimethacrylate, N,N′-(1,2-dihydroxyethylene)bisacrylamide, di(ethyleneglycol)dimethacrylate, di(trimethylolpropane) tetraacrylate, diurethanedimethacrylate, N,N-ethylenebis(acrylamide), ethylene glycoldimethacrylate, glycerol 1,3-diglycerolate diacrylate, glyceroldimethacrylate, glycerol propoxylate triacrylate, 1,6-hexanedioldiacrylate, 1,6-hexanediol dimethacrylate, 1,6-hexanediol ethoxylatediacrylate, 1,6-hexanediylbis[oxy(2-hydroxy-3,1-propanediyl)]bisacrylate, hydroxypivalyl hydroxypivalatebis[6-(acryloyloxy)hexanoate], neopentyl glycol diacrylate, neopentylglycol propoxylate diacrylate, pentaerythritol diacrylate monostearate,pentaerythritol tetraacrylate, pentaerythritol triacrylate,poly(propylene glycol) diacrylate, poly(propylene glycol)dimethacrylate, 1,3,5-triacryloylhexahydro-1,3,5-triazine,tricycle[[-]]decanedimethanol diacrylate, trimethylolpropane ethoxylatemethyl ether diacrylate, trimethylolpropane ethoxylate triacrylate,trimethylolpropane ethoxylate triacrylate, trimethylolpropane ethoxylatetriacrylate, trimethylolpropane propoxylate triacrylate,trimethylolpropane triacrylate, trimethylolpropane trimethacrylate,tri(propylene glycol) diacrylate and tris[2-(acryloyloxy)ethyl]isocyanurate.

In some embodiments, the dry weight ratio of crosslinker capable ofundergoing free radical polymerization to free radical initiator forinitiation of further crosslinking reactions between saccharide residuesand the crosslinker ranges between 2:0.5 and 20:1, including between 5:1and 10:1. In certain embodiments, the dry weight concentration ofcrosslinker in the binder composition may advantageously vary from 2-30%by weight (wt. %), such as from 5-20 wt. % and from 5-15 wt. %.

In further embodiments, a free radical initiator for use in thedisclosed technology may comprise inorganic peroxides selected from thegroup consisting of hydrogen peroxide, peroxodisulfates such as themono- or di-alkali metal salts thereof, ammonium salts ofperoxodisulfuric such as their mono- and di-sodium salts and ammoniumsalts, ammonium, sodium or potassium persulfates, and mixtures thereof.

In still further embodiments, a free radical initiator for use inaccordance with the instant disclosure may comprise organic peroxides,alkyl hydroperoxides, tert-butyl hydroperoxide, cumyl hydroperoxide,cumene hydroperoxide, dialkyl and diaryl peroxides such as di-tert-butyland dicumyl peroxide, di-tert-amyl peroxide, benzyl peroxide, butanoneperoxide, lauroyl peroxide,2,5-bis(tert-butylperoxy)-2,5-dimethylhexane,1,1-bis(tert-butylperoxy)-3,3,5-trimethyl-cyclohexane,1,1-bis(tertamylperoxy)cyclohexane, tert-butyl peroxybenzene andtert-butylperoxy 2-ethylhexyl carbonate.

In additional embodiments, azo compounds may be used as free radicalinitiators in the disclosed binder compositions and may be selected fromthe group consisting of azobis(isobutyronitrile) (AIBN),2,2′-azobis(2-methylpropionitrile), 4,4′-azobis(4-cyanovaleric acid),1,1′-azobis(cyclohexanecarbonitrile),2,2-azobis(2,4-dimethylvaleronitrile) and 2,2′-azobis(amidinopropyl)dihydrochloride (AIBA).

In certain embodiments, oxidizing agents for use as oxidation-reduction(redox) initiators may be selected from the inorganic peroxides andfunctionalized peroxides disclosed herein. In some embodiments, reducingagents for use with the disclosed technology may be selected from thegroup consisting of sulfur compounds with a low oxidation state, such asalkali metal sulfites, potassium and/or sodium sulfite, alkali metalsulfites such as potassium and/or sodium hydrogen sulfite, alkali metalmetabisulfites such as potassium and/or sodium metabisulfite, potassiumand/or sodium alkali metal salts such as potassium and/or sodium saltsof aliphatic sulfinic compounds, alkali metal hydrogen sulfides such aspotassium and/or sodium hydrogen sulfide, salts of polyvalent metalssuch as iron(II) sulfate, iron(II) ammonium sulfate, iron (II)phosphate, and cerium salts such as ceric ammonium nitrate.

In some embodiments, the disclosed binder compositions advantageouslyexhibit a reduced tendency to form dark brown-colored binder resins,e.g. the disclosed binders may comprise light brown to nearly whitecolors similar to those observed in champagne, tapioca, vanilla custard,papyrus, nude and wheat.

In further embodiments, the aqueous binder compositions disclosed hereincomprise one or more polysaccharides crosslinked by an azetidiniumcrosslinker comprising at least two azetidinium groups, and furthercomprises a polycarboxylic acid and a free radical initiator for theinitiation of additional crosslinking reactions between thepolysaccharide residues and the polycarboxylic acid. The disclosedaqueous binder compositions may, in certain embodiments, beneficiallyexhibit improved bond strength upon curing.

In some embodiments, the binder compositions disclosed herein, as wellas binders produced therefrom, are essentially formaldehyde-free, i.e.the binder compositions comprise less than about 1 ppm formaldehydebased on the weight of the composition, and advantageously do not emitdetectable formaldehyde levels.

In alternative embodiments, the disclosed aqueous binder compositionsmay comprise additive compounds selected from the group consisting ofcoupling agents, dyes, antifungal agents, antibacterial agents,hydrophobic compounds and other additives known in the art for suchbinder applications. In embodiments where silicon-containing couplingagents are incorporated in the disclosed binders, such agents aregenerally present at a concentration from about 0.1% to about 1% byweight based on the weight of the solids in the binder composition.These additives may beneficially enhance the adhesive, mechanical andadditional properties of the binder while advantageously complying withstringent environmental and health related requirements.

Without wishing to be bound by any general or particular theory, it isbelieved that the curing of the disclosed binder compositions generateshighly-crosslinked, high molecular weight polymers that beneficiallyenhance the relevant properties of the binder.

As used herein, the term “binder composition” includes any compositioncapable of binding loosely assembled matter, either as such or uponcuring. In some embodiments, the binder composition comprises an aqueouscurable and/or uncured composition comprising the starting materials forforming a thermosettable binder resin, including any reaction product(s)resulting from the reaction or partial reaction of the startingmaterials and/or additives.

As used herein, the term “aqueous” relates to a solution and/ordispersion comprising water as a solvent including compositions andmixtures comprising water and one or more additional solvents. An“aqueous binder composition” in accordance with the instant disclosuremay comprise a solution or partial solution of one or more bindercomponents or a dispersion, such as an emulsion or suspension.

In some embodiments, the solid content of an aqueous binder compositiondisclosed herein may range from 5-95 wt. %, including from 8-90 wt. %and from 10-85 wt. %, based on the weight of the total aqueous bindercomposition. In embodiments where a binder as disclosed herein isutilized for the production of mineral wool insulation, the solidcontent concentration of the aqueous binder composition may be 5-25 wt.%, such as from 8-20 wt. %, from 10-20 wt. % and 12-18 wt. %, based onthe total weight of the aqueous binder composition. When used as abinder in wood boards, such as plywood, particle boards and fiberboards, the solid content of an aqueous binder composition disclosedherein may range from 50-95 wt. %, including 50-90 wt. %, 55-85 wt. %and 60-80 wt. % of the total weight of the aqueous binder composition.

In some embodiments, the aqueous binder compositions disclosed hereinmay comprise nanoparticles derived from inorganic materials selectedfrom the group consisting of metal oxides, MgO, CaO, Al₂O₃ and CaCO₄. Inadditional embodiments, nanoclays may be incorporated in the disclosedaqueous binder formulations, which may be selected from the groupconsisting of bentonite, kaolinite, hectorite, halloysite,organically-modified nanoclays and mixtures thereof. In furtherembodiments, these materials may be present in the aqueous bindercompositions of the instant disclosure at a concentration of 0.1-10 wt.%, such as 0.1-5 wt. % of the solid content of the total bindercomposition.

In additional embodiments, the chemical components of the disclosedbinder compositions may be transported separately and combined prior toprocessing, for instance in a manufacturing plant. In alternativeembodiments, a pre-reacted crosslinked starch may be transportedseparately from and later combined/formulated with a crosslinker and/orfree radical initiator for producing an aqueous binder composition.

In some embodiments, the disclosed binders may be used to bond acollection of non- or loosely assembled matter. The collection of mattermay comprise any fibrous collection of matter selected from the groupconsisting of mineral fibers, slag wool fibers, stone wool fibers, glassfibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers,polyimide fibers, polyester fibers, rayon fibers and cellulosic fibers.In additional embodiments, materials selected from the group consistingof coal, cellulosic fibers, wood shavings, saw dust, wood pulp, groundwood, wood chips, wood strands, wood layers, other natural fibers, suchas jute, flax, hemp, straw, wood veneers, facings, wood particles,mineral fibers and additional woven and non-woven materials may be boundby the aqueous binder compositions of the present technology.

In further embodiments, the binder compositions disclosed herein may beused to produce and manufacture insulation products and articles,including but not limited to insulation products and articles comprisingmineral fibers. For instance, the fibers may be bonded together by anaqueous binder composition disclosed herein to form a fiber mat whichmay be further processed into an insulation product or article. In stillfurther embodiments, the fibers comprise a concentration of 70-99% byweight (wt. %) with respect to the total weight of the insulationproduct or article.

In certain embodiments, the disclosed aqueous binder compositions may beused to bond materials selected from the group consisting of cellulosicparticles, cellulosic fibers, wood shavings, wood layers, wood sheets,wood pulp and other materials commonly used to manufacture compositewood boards, including fiber boards, particle boards, oriented strandboards and plywood. In related embodiments, a wood board comprising anaqueous binder composition as disclosed herein may comprise 1) athickness of 6-30 mm; 2) a modulus of elasticity, also known as Young'smodulus, of at least about 1000 N/mm²; 3) a bending strength of at leastabout 5 N/mm²; and/or 4) an internal bond strength of at least 0.10N/mm². In additional embodiments, the concentration of aqueous bindercomposition in the wood board product or article may be about 5-30 wt. %of the total weight of the wood board product or article, includingabout 9-20 wt. %.

In some embodiments, an aqueous binder composition as disclosed hereinmay be effectively applied to a fiber, particulate and sheet material,for instance by spraying. Additional techniques for applying thedisclosed binder compositions include roller/rolling applications, andmixing and/or tumbling a collection of matter with the bindercomposition. While not limiting or binding the present technology to anyparticular theory, it is believed that the binder composition forms agel following the evaporation of endogenous water that bonds theparticulate material together when arranged into a desirable assembly asdescribed herein. The reactive binder components, upon curing, form anessentially water insoluble macromolecular binder resin. In certainembodiments, the curing of an aqueous binder composition disclosedherein may beneficially exhibit increased adhesion, durability and waterresistance as compared to the same binder prior to or in the absence ofcuring. In additional embodiments, the binders of the present disclosuremay be cured at temperatures between ambient temperatures, for instancefrom about 10-25° C., up to 280° C.

In some embodiments, the present technology provides for processes forthe preparation of an article or product comprising fibrous materials,particulate materials and sheet materials by the application andoptional curing of an aqueous binder composition disclosed herein. Inadditional embodiments, an article or product may be further processedfollowing its initial production, which may be selected from insulationproducts and wood boards as disclosed herein. In further embodiments, aprocess for the manufacturing of an article or product comprising anassembly of fibers, cellulosic particles, and sheets may comprise (i) aneffective concentration or amount of (a) a monosaccharide and/orpolysaccharide, (ii) an effective concentration or amount of (b) anazetidinium crosslinker, (iii) the successive or simultaneousapplication of (a) and (b), optionally as an aqueous compositioncomprising (a) and (b), and optionally (a) crosslinked by (b), onto amaterial selected from the group consisting of fibrous materials,cellulosic particulate materials and sheet materials to produce aresinated material, and (v) curing the resinated material and allowingfor the evaporation of excess water.

In related embodiments, a process for the manufacturing of an assemblyof fibrous or cellulosic particle or sheet material may comprise thesuccessive or concomitant application onto fibrous or cellulosicparticulate or sheet material of an aqueous binder composition asdisclosed herein comprising (a) crosslinked with (b), and optionally (c)an additional crosslinker and/or (d) a free radical initiator,optionally in the form of a single aqueous composition, to produce aresinated material, optionally allowing for additional crosslinking tooccur, subjecting the resulting aqueous composition to curing conditionsand allowing for the evaporation of excess water.

In further related embodiments, one or more polymerization and/orcopolymerization reactions of (b) with (a) may be performed at atemperature ranging from ambient temperature, for instance 10-25° C., upto 200° C., such as from 40-95° C. Additional crosslinking with (c),optionally in the presence of (d), may also be performed within the sametemperature ranges.

In certain embodiments, curing may be performed at a temperature of90-200° C., including 140-190° C. and 160-180° C. In some embodimentsrelated to the manufacture of wood boards comprising the aqueous bindersdisclosed herein, curing is performed while the material is subjected topressing.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the disclosed technology are disclosed in thedrawings as filed, wherein:

FIG. 1 shows a kinetic curing profile at 160° C. for binder formulationscomprising 70% Stadex®79+20% CA1025+10% DEGDMA+1%azobis(cyclohexanecarbonitrile) (ABCN).

FIG. 2 shows a kinetic curing profile at 160° C. for binder formulationscomprising 70% Stadex® 79+20% CA1025+10% HEMA+1%azobis(cyclohexanecarbonitrile) (ABCN).

FIGS. 3A and 3B show the modulus as a function of temperature measuredat two different frequencies (1 Hz and 10 Hz), as determined by dynamicmechanical analysis (DMA), of two different binder compositions.

FIGS. 4A and 4B show the modulus as a function of temperature measuredat two different frequencies (1 Hz and 10 Hz), as determined by dynamicmechanical analysis (DMA), of two different binder compositions.

EXAMPLES

For the production of the disclosed binder compositions, the starchpolymers Stadex® 79, 125 and 201, and ETHYLEX® 2005, 2040 and 2095, werepurchased from Tate & Lyle PLC (London, UK). The azetidinium crosslinkerCA1025 was purchased from SOLENIS™ (Wilmington, Del., USA). Finally,hydroxyethyl methacrylate (HEMA), diethyleneglycol dimethacrylate(DEGDMA), and 1,1′-azobis (cyclohexanecarbonitrile) (ABCN) werepurchased from MilliporeSigma (a division of Merck KGaA, Darmstadt,Del.).

Preparation of Binder Solution Compositions

A desired amount of saccharide was dissolved in water and stirredconstantly for a sufficient period of time (for instance, 45 minutes inthe case of starch) at room temperature. As necessary, the temperaturewas raised up to 80° C. in order to completely dissolve the saccharidein water. For crosslinking reaction, the required amount of azetidiniumcrosslinker was added to the saccharide solution. The saccharide wasallowed to crosslink by stirring at an elevated temperature and/or byadding a small amount of free radical initiator. The resulting mixturewas impregnated on a glass veil and subjected to curing. Samples wereprepared from the cured glass veil and subjected to different tests asdescribed below.

Additionally, a portion of the saccharide mixture comprising theazetidinium crosslinker was combined with HEMA or DEGDMA and freeradical initiator ABCN. The resulting aqueous compositions were stirredcontinuously at a pre-set temperature to obtain a complex crosslinkedpolymer network.

In accordance with certain embodiments, the crosslinking of starch withan azetidinium crosslinker can take place between various molecules suchas amylose to amylose, amylose to amylopectin, or amylopectin toamylopectin. When these linkages are formed, further crosslinking and/orcopolymerization reactions can be carried out with polycarboxyliccrosslinkers using a free radical initiator as described herein, withfree radical initiation being promoted, in some embodiments, by anincrease of temperature and/or the introduction of radiation sourcessuch as IR, RF or UV radiation. The resulting aqueous composition wasapplied to a glass veil and cured. Samples were prepared from the curedveil and subjected to different tests as described below.

Kinetic Evaluation of Curing

Glass microfiber (Whatman™) GF/A filters were impregnated with bindersolution as described above prior to curing at various time points at aset temperature. Samples were kept on the top shelf in an oven to avoidthe potentially high moisture content inside the oven during curing. Foreach binder solution, samples were cured for a time period of 3 minutesto 20 minutes. After curing, each cured sample was cut into anappropriate size of defined length (150 mm) and width (20 mm), andmechanical testing was performed for stiffness and bond strengthanalysis on the cured samples. The results of the kinetic study or curerate study are presented in FIGS. 1 and 2 .

Bond Strength Analysis Using the Veil Method

Commercial PF (phenol formaldehyde) impregnated (A4 size) glass fiberveils were placed into a benchtop muffle furnace oven for 30 minutes at600° C. in order to burnout the PF binder, and were then allowed to coolfor 30 minutes. The resulting veil samples were then weighed.

Next, approximately 400 g binder solution samples were poured into diptrays, and the resulting veil samples were fully immersed into thebinder solution samples. The impregnated veils were then cured atdefined temperatures for defined periods of time. The resulting bindercontent was then measured and bond strength determined as describedbelow.

The bond strength of the cured binder impregnated veils was determinedby a mechanical testing instrument (M350-10CT). For each test, a curedbinder-impregnated A4-type veil was cut into eight (8) equal strips.Each strip was tested separately using a 50 kg load cell (DBBMTCL-50 kg)at an automated test speed of 10 mm/min. The mechanical testinginstrument was controlled using winTest™ Analysis software (TestometricCompany Ltd., Rochdale, UK). The glass veil tensile plates were attachedto the mechanical testing instrument, with 100 mm gaps between plates.Samples were placed vertically in the grippers, with the forcemeasurement tarred to zero. Various parameters such as maximum load atpeak, stress at peak and modulus at peak were evaluated by the software,and data presented as an average of the eight (8) samples, with thestandard deviation also determined. The average maximum load at peak orstress at peak is defined as the bond strength of the sample.

Evaluation of Weathering Stability

An electronically controlled autoclave system (a steam pressure vessel)was then used to sterilize the cured binder veils samples for strengthtesting. Cured binder impregnated veils were placed in an autoclave(J8341, Vessel: PVO2626 with associated safety valve, door interlock andintegrated pipework) system. Samples were treated at 90% humidity and ata temperature ranging from 40-110° C. (full cycle), at a pressure of upto 2.62 bar, for three (3) hours. The samples were dried completely inorder to ensure no moisture remained on the veils. The autoclave treatedsamples were then tested for bond strength using the M350-10CTtestometric machine (M350-10CT), and the results were compared withthose of untreated samples.

Dynamic Mechanical Analysis (DMA)

Binder impregnated Whatman™ Grade 3 Filter Papers (MilliporeSigma, adivision of Merck KGaA, Darmstadt, DE; dimensions of 35 mm×10 mm×0.36mm) was prepared with 100 grams of pre-mixed aqueous binder solutioncomprising 20% solids. Binder impregnated filter strips were kept atambient temperature (approximately 22° C.) for about one hour forinitial drying. Each strip was then carefully mounted on a DMA sampleholder. The DMA tests were performed on a dual cantilever mode using twofrequencies (1 Hz and 10 Hz) at 1° C./min. The modulus was measured as afunction of scanning temperature, and the results are presented in FIGS.3-4 .

Example 1

The determination of binder solid weight loss upon curing at 140° C. for2 hours is presented in Table 1. Aqueous binder compositions (solutions)as prepared above were brought to a solid content of 22.5%. About 12 gof binder solution was placed into an aluminum petri dish, which waskept in an oven at 140° C. for 2 hours. The theoretical and experimentalsolid concentration was measured, and the solid loss was calculated. Thebinder compositions comprise starch as a polysaccharide, azetidiniumcompound as a crosslinker, acrylates (HEMA: 2-hydroxyethyl methacrylate,or DEGDMA: di(ethylene glycol)dimethacrylate) as an additionalcrosslinker, and ABCN (1,1′-azobis(cyclohexanecarbonitrile) as a radicalinitiator.

TABLE 1 Solid Loss Binder Materials Composition (%) Stadex ® 79/CA102590:10 2.4 Stadex ® 79/CA1025/HEMA/ABCN 80:10:10:1 0.12 Stadex ®79/CA1025 85:15 1.7 Stadex ® 79/CA1025/HEMA/ABCN 75:15:10:1 0.003Stadex ®79/CA1025 80:20 3.49 Stadex ®79/CA1025/HEMA/ABCN 70:20:10:1 3.49Stadex ®79/CA1025/DEGDMA/ABCN 70:20:10:1 10.04

Example 2

The kinetic evaluation of curing was determined at 160° C. for binderformulations of Stadex® 79/CA1025/DEGDMA/ABCN, at a ratio of 70:20:10:1,as shown in FIG. 1 , with a standard deviation of five replicates. Thebinder composition was prepared and the stiffness of correspondingsample was measured according to the procedure described in the previoussection.

Example 3

The kinetic evaluation of curing was determined at 160° C. for binderformulations of Stadex® 79/CA1025/HEMA/ABCN, at a ratio of 70:20:10:1,as presented in FIG. 2 , with a standard deviation of five replicates.The binder composition was prepared according to the description givenin the previous section.

In Examples 2 and 3, some samples were exposed to an additional step,i.e. UV radiation for a time period of 5 minutes, in order to enhancecuring, with the results compared to a corresponding un-exposed sample.The binder compositions show good curing time in the range of 3-5minutes. Additionally, curing may be enhanced by UV radiation treatmentprior to temperature curing.

Example 4

The bond strength of various binder formulations comprising amonosaccharide (dextrose monohydrate (DMH)), disaccharide (maltosemonohydrate (maltose MH)) and polysaccharide (maltodextrin, from 3 to 19saccharide units), and their combination with starch (Stadex® 79),CA1025, HEMA, and optionally ABCN, is presented. The mechanical testswere performed on cured (180° C. for 15 minutes) veil samples at dryconditions, for both unweathered and weather treated veils, and theresults are presented with standard deviation based on eight replicates,as shown in Table 2.

TABLE 2 Unweathered Veil Weathered Veil Samples Samples Average BondStandard Average Bond Standard Strength Deviation Strength DeviationFormulations (N) (+/−) (N) (+/−) DMH/CA1025: 80:20 65.64 13.61 68.6111.13 DMH/CA1025/HEMA/ABCN: 70.17 17.09 70.45 7.23 70:20:10:1 MaltoseMH/CA1025: 80:20 89.17 17.95 75.19 16.68 Maltose MH/CA1025/ 82.63 11.5270.56 9.71 HEMA/ABCN: 70:20:10:1 Maltodextrin/CA1025: 80:20 104.31 7.62104.67 8.39 Maltodextrin/CA1025/HEMA/ 100.40 9.70 100.75 7.45 ABCN:70:20:10:1 Stadex ® 79/DMH/CA1025/ 109.13 14.10 102.04 14.19 HEMA/ABCN:50:20:20:10:1 Stadex ® 79/Maltose MH/ 103.49 10.06 97.57 5.40CA1025/HEMA/ABCN: 50:20:20:10:1 Stadex ® 79/Maltodextrin/ 112.16 5.9499.48 8.53 CA1025/HEMA/ABCN: 50:20:20:10:1

Example 5

Bond strength analysis of various binder formulations comprising starch,azetidinium crosslinker (CA1025), with and without acrylate (HEMA) andradical initiator ABCN or Ce⁴⁺) in the compositions, was performed. Thebond strength is defined as the maximum load at which the veilimpregnated cured samples breaks down. Results are shown for unweatheredand weather treated veil samples. These impregnated veils were cured ata desired temperature (e.g. 180° C.) for 15 minutes and mechanical testswere performed at dry conditions. The results are presented withstandard deviation based on sixteen replicates, as shown in Table 3. Theinvention compositions show high bond strength for all samples. It isnoted that the bond strength either remained in the same range withinthe statistical deviation or improved after weather treatment.

TABLE 3 Unweathered Veils Weather Treated Veils Samples Samples AverageBond Standard Average Bond Standard Strength Deviation StrengthDeviation Formulations (N) (+/−) (N) (+/−) Stadex ® 79/CA1025: 81.275.70 91.82 5.28 92.5:7.5 Stadex ® 79/CA1025: 84.81 7.84 95.90 9.52 90:10Stadex ® 79/CA1025: 95.09 7.46 — — 87.5:12.5 Stadex ® 94.01 9.24 — —79/CA1025/Ce⁴⁺: 87.5:12.5:1 Stadex ® 79/CA1025: 102.79 14.36 — — 85:15Stadex ® 79/CA1025/ 99.84 13.08 — — Ce⁴⁺: 85:15:1 Stadex ® 79/CA1025:92.42 9.65 95.17 7.83 80:20 Stadex ® 94.67 9.55 98.32 13.29 79/CA1025/HEMA: 70:20:10 Stadex ® 84.39 6.59 92.06 8.53 79/CA1025/HEMA/ABCN: 82.5:7.5:10:1 Stadex ® 94.58 9.39 98.97 9.99 79/CA1025/HEMA/ ABCN:80:10:10:1 Stadex ® 100.08 14.36 90.62 5.24 79/CA1025/HEMA/ ABCN:70:20:10:1

Example 6

Modulus analysis by DMA was carried out for binder formulationscomprising Stadex® 79/CA1025, comprising a ratio of 85:15, and Stadex®79/CA1025/HEMA/ABCN comprising a ratio of 75:15:10:1, as presented inFIG. 3A and FIG. 3B, respectively. A significantly higher modulus wasobserved for the second formulation (FIG. 3B) as compared to the firstformulation (FIG. 3A). Similar results were obtained for the compositioncomprising Stadex® 79/CA1025/HEMA/ABCN at a ratio of 70:20:10:1 (FIG.4B) as compared to that of Stadex® 79/CA1025 at a ratio of 80:20 (FIG.4A).

Example 7

The experiments of Example 5 were repeated with different starches,except that the curing temperature was 190° C. and the curing time was10 minutes. The data obtained is shown in the tables below.

Veil bond strength Av. Dry Standard Av. Wet Standard Strength DeviationStrength Deviation Formulations (N) (+/−) (N) (+/−) Stadex ® 125/CA1025:98.46 8.12 77.72 12.44 80:20 Stadex ® 125/CA1025: 95.90 10.47 85.33 6.4475:25 Stadex ® 125/CA1025: 94.37 7.88 85.82 6.21 70:30 Stadex ®125/CA1025: 100.38 5.96 83.69 6.45 65:25:10:1

Veil bond strength Av. Dry Standard Av. Wet Standard Strength DeviationStrength Deviation Formulations (N) (+/−) (N) (+/−) Stadex ® 201/CA1025:107.87 14.38 97.57 5.86 80:20 Stadex ® 201/CA1025: 109.39 12.91 104.687.22 75:25 Stadex ® 201/CA1025: 118.29 6.80 92.43 3.12 70:30 Stadex ®201/CA1025: 95.22 4.23 85.63 10.44 65:25:10:1

Veil bond strength Av. Dry Standard Av. Wet Standard Strength DeviationStrength Deviation Formulations (N) (+/−) (N) (+/−) Ethylex ®2005S/CA1025: 101.02 9.07 93.69 12.13 80:20 Ethylex ® 2005S/CA1025:98.31 5.57 83.41 9.31 75:25 Ethylex ® 2005S/CA1025: 97.85 5.26 91.196.94 70:30 Ethylex ® 2005S/CA1025: 90.27 7.70 91.12 8.97 65:25:10:1Ethylex ® 2040/CA1025: 112.27 9.55 89.37 8.97 80:20 Ethylex ®2040/CA1025: 112.06 8.42 76.99 8.52 75:25 Ethylex ® 2040/CA1025: 102.218.65 85.13 8.34 70:30 Ethylex ® 2040/CA1025: 93.58 7.11 80.64 5.4965:25:10:1

Veil bond strength Av. Dry Standard Av. Wet Standard Strength DeviationStrength Deviation Formulations (N) (+/−) (N) (+/−) Ethylex ®2095/CA1025: 91.62 3.99 87.38 8.07 80:20 Ethylex ® 2095/CA1025: 101.2514.15 79.37 5.64 75:25 Ethylex ® 2095/CA1025: 109.23 7.76 82.57 9.7070:30 Ethylex ® 2095/CA1025: 109.62 5.81 7574 6.85 65:25:10:1

The above examples make use of commercially available starches asmentioned above. As shown below by way of viscosity measurements,Stadex® starches are low molecular weight starches, Ethylex® 2040 and2095 starches are higher molecular weight starches.

TABLE 6 Viscosity Measurement of Modified Starches

Viscosity was measured using a Brookfield DV-II+Pro viscometer (AMETEKGB Ltd. Brookfield, Harlow, Essex, UK). All measurements were performedat a constant temperature.

Viscosity Concentration Temp. Value Sample Name (wt. %) (° C.) (cps)Comments Stadex ® 79 20 35 6.67 Stadex ® 125 20 35 8.40 Stadex ® 201 2035 4.17 Ethylex ® 2005 15 35 67 Ethylex ® 2005 20 35 275 Ethylex ® 204020 35 xxx The viscosity exceeded the highest detection limit of themachine. Ethylex ® 2040 15 35 9900 Highly viscous. Ethylex ® 2095 20 35xxx The viscosity exceeded the highest detection limit of the machine.Ethylex ® 2095 15 35 xxx The viscosity exceeded the highest detectionlimit of the machine. Ethylex ® 2095 10 70 >101,000 Highly viscous(below 70° C. machine did not detect).

The invention claimed is:
 1. An assembly of matter selected frominsulation products comprising mineral fibers and composite wood boardscomprising cellulosic particulate or sheet material, bonded together byan aqueous curable binder composition consisting of (a) amonosaccharide, (b) an azetidinium cross-linker, optionally (a)cross-linked by (b), optionally (c) a cross-linker capable of undergoingfree radical polymerization to further cross-link (a), optionallytogether with (d) a free radical initiator, optionally one or morecoupling agents, dyes, antifungal agents, antibacterial agents,hydrophobes, metal oxide nanoparticles of MgO, CaO, Al₂O₃ and/or CaCO₄,nanoclays of montmorillonite, bentonite, kaolinite, hectorite,halloysite and/or organically modified nanoclays, and mixtures thereof,and water, or by a binder obtained by subjecting to curing conditionssaid aqueous curable binder composition.
 2. The assembly of matter ofclaim 1, wherein the (b) azetidinium cross-linker comprises apolyazetidinium comprising at least two monomeric units of the generalformula

wherein R¹ comprises a C₁-C₂₅ alkanediyl group optionally substitutedwith a hydroxyl group, carboxyl functional group or an amino group, R²comprises independently R¹ or —R₃—NH—C(O)—R₄—, wherein R₃ and R₄comprise independently C₁-C₂₅ alkanediyl, Y¹ and Y³ compriseindependently H or a C₁-C₅ alkyl group optionally substituted with ahydroxyl group, an amino group or a carboxyl group, Y² comprises ahydroxyl group or independently Y¹, and X⁻ comprises a halogen counterion.
 3. The assembly of matter of claim 1, wherein the dry weight ratioof the (a) monosaccharide to the (b) azetidinium cross-linker comprisesa ratio of 99/1 to 60/40.
 4. The assembly of matter of claim 1characterized by one or more of the following features: wherein theaqueous curable binder composition consists of the (a) monosaccharide,the (b) azetidinium cross-linker, (a) cross-linked with (b), the (c)cross-linker capable of undergoing free radical polymerization, the (d)free radical initiator, and water; wherein the aqueous curable bindercomposition consists of the (a) monosaccharide, the (b) azetidiniumcross-linker, (a) cross-linked with (b), the (c) cross-linker capable ofundergoing free radical polymerization, the (d) free radical initiator,and water, wherein the (c) cross-linker capable of undergoing freeradical polymerization is selected from the group consisting ofpolycarboxylic acids, acrylamide, methacrylamide, acrylate, acrylicacids and their salts, acrylonitrile, bisphenol acrylics, carbohydratemonomers, fluorinated acrylics, maleimide and mixtures thereof; whereinthe aqueous curable binder composition consists of the (a)monosaccharide, the (b) azetidinium cross-linker, (a) cross-linked with(b), the (c) cross-linker capable of undergoing free radicalpolymerization, and water, wherein the (c) cross-linker capable ofundergoing free radical polymerization is present in the range of 1-40wt. % based on the total dry weight of the aqueous curable bindercomposition; wherein the aqueous curable binder composition consists ofthe (a) monosaccharide, the (b) azetidinium cross-linker, (a)cross-linked with (b), the (c) cross-linker capable of undergoing freeradical polymerization, the (d) free radical initiator, and water,wherein the (d) free radical initiator is (i) selected from the groupconsisting of inorganic peroxides, organic peroxides, reducing agents,azo compounds, redox initiators, photo-initiators, and mixtures thereof,and (ii) present in the range of 0.05-5 wt. % based on the total dryweight of the aqueous curable binder composition.
 5. The assembly ofmatter of claim 1 being an insulation product comprising a mineral woolmat.
 6. The assembly of matter of claim 1 being a composite wood boardselected from wood fiber board, wood particle board, or plywood.
 7. Aprocess for the manufacture of a product which comprises a bondedassembly of fibrous material or cellulosic particulate or sheetmaterial, said method comprising (i) the provision of (a) amonosaccharide, (ii) the provision of (b) an azetidinium cross-linker,(iii) the application of (a) and (b) as an aqueous curable bindercomposition consisting of (a), (b), optionally (a) cross-linked by (b),optionally (c) a cross-linker capable of undergoing free radicalpolymerization to further cross-link (a), optionally together with (d) afree radical initiator, optionally one or more coupling agents, dyes,antifungal agents, antibacterial agents, hydrophobes, metal oxidenanoparticles of MgO, CaO, Al₂O₃ and/or CaCO₄, nanoclays ofmontmorillonite, bentonite, kaolinite, hectorite, halloysite and/ororganically modified nanoclays, and mixtures thereof, and water ontofibrous material or cellulosic particulate or sheet material to produceresinated material, and (iv) subjecting the resulting resinated materialto curing conditions and allowing for evaporation of excess water. 8.The process of claim 7 characterized by one or more of the followingfeatures: wherein the cross-linking between (a) and (b) and optionalfurther cross-linking with (c), in the presence of (d), is effected at atemperature ranging from ambient temperature to 200° C., during a periodof time to generate the desired cross-linked material; wherein thecross-linking between (a) and (b) is effected by free radicalinitiation; wherein the resinated material is subjected to UV radiationprior to being subjected to temperature curing as the curing conditions;wherein the resinated material is subjected to temperature curing at atemperature ranging from 90-200° C. as the curing conditions.
 9. Anaqueous binder composition consisting of (a) a monosaccharidecross-linked with (b) an azetidinium cross-linker, (c) a cross-linkercapable of undergoing free radical polymerization, optionally (d) a freeradical initiator, and water.
 10. The aqueous binder composition ofclaim 9, wherein the (c) cross-linker capable of undergoing free radicalpolymerization is selected from the group consisting of polycarboxylicacids, acrylamide, methacrylamide, acrylate, acrylic acids and theirsalts, acrylonitrile, bisphenol acrylics, carbohydrate monomers,fluorinated acrylics, maleimide and mixtures thereof.
 11. The aqueousbinder composition of claim 9, wherein the (b) azetidinium cross-linkercomprises a polyazetidinium comprising at least two monomeric units ofthe general formula

wherein R¹ comprises a C₁-C₂₅ alkanediyl group optionally substitutedwith a hydroxyl group, carboxyl functional group or an amino group, R²comprises independently R¹ or —R₃—NH—C(O)—R₄—, wherein R₃ and R₄comprise independently C₁-C₂₅ alkanediyl, Y¹ and Y³ compriseindependently H or a C₁-C₅ alkyl group optionally substituted with ahydroxyl group, an amino group or a carboxyl group, Y² comprises ahydroxyl group or independently Y¹, and X⁻ comprises a halogen counterion.
 12. The aqueous binder composition of claim 9, wherein the (d) freeradical initiator is (i) selected from the group consisting of inorganicperoxides, organic peroxides, reducing agents, azo compounds, redoxinitiators, photo-initiators, and mixtures thereof, and (ii) present inthe range of 0.05-5 wt. % based on the total dry weight of the aqueousbinder composition.